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Dyna 60 Service Manual

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SERVICE MANUAL FOR
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FREQUENCY CONTROL SYSTEM
DynA60

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English SUPDOC_SM_TDN001-0.ORD 10.7.2013
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134074 07.2013

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Original instructions SUPDOC_SM_TDN0010100-0 PS18733 10.7.2013

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

Table of contents

1 GENERAL INTRODUCTION................................................................................................................ 4
1.1 Foreword: About this manual ........................................................................................................................4
1.2 Symbols Used in this Manual........................................................................................................................4
1.3 Safety Alert Symbols and Signal Words .......................................................................................................4
1.4 Questions and Comments ............................................................................................................................5
1.5 Manual Use ................................................................................................................................................... 5
1.6 Terminology ..................................................................................................................................................6
1.7 Directives and standards ..............................................................................................................................7
1.7.1 CE/CSA/UL/CCC ......................................................................................................................................7
1.7.2 EMC ..........................................................................................................................................................7
2 SAFETY FIRST! ................................................................................................................................... 9
2.1 Personal protective equipment (PPE)...........................................................................................................9
2.1.1 Fall Protection ...........................................................................................................................................9
2.2 Fire Safety ..................................................................................................................................................... 9
2.3 Main isolation switch ...................................................................................................................................10
2.4 Safety during maintenance .........................................................................................................................10
3 IDENTIFICATION............................................................................................................................... 12
3.1 Manufacturer ...............................................................................................................................................12
3.1.1 Main sticker ............................................................................................................................................. 12
3.2 Factory code example (Factory: TDN)........................................................................................................13
3.3 Konecranes code example (Konecranes: DynA60, Factory: TDN) ............................................................13
4 CONSTRUCTION .............................................................................................................................. 14
4.1 Intended use of the frequency converter ....................................................................................................14
4.2 Main components........................................................................................................................................15
4.2.1 Display panel ..........................................................................................................................................16
4.2.2 Terminals ................................................................................................................................................16
4.2.3 EMC Filter ...............................................................................................................................................19
4.2.4 Braking resistor ....................................................................................................................................... 20
5 PREPARING THE PRODUCT FOR USE .......................................................................................... 21
5.1 Transport and storage.................................................................................................................................21
5.2 Safety precautions before installation.........................................................................................................21
5.3 Mounting and installation ............................................................................................................................22
5.3.1 Dimensions .............................................................................................................................................22
5.3.2 Mounting .................................................................................................................................................23
6 USER INTERFACE ............................................................................................................................ 24
6.1 The display panel ........................................................................................................................................24
6.2 Display options ............................................................................................................................................ 24
6.2.1 Drive status ............................................................................................................................................. 24
6.2.2 Display messages ...................................................................................................................................24
6.3 Navigation on the control keypad ...............................................................................................................25
6.3.1 Using buttons ..........................................................................................................................................25
6.3.2 Setting parameters..................................................................................................................................25
6.3.3 Changing a parameter value...................................................................................................................26
7 PARAMETERS .................................................................................................................................. 27
7.1 General Description .................................................................................................................................... 28
7.2 PARAMETER DESCRIPTIONS..................................................................................................................29
7.2.1 Viewing monitoring values (group 00) ....................................................................................................29
7.2.2 General ...................................................................................................................................................30
7.2.3 Motor .......................................................................................................................................................30
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 2/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

7.2.4 U/f settings .............................................................................................................................................. 31

7.2.5 Brake control ........................................................................................................................................... 31
7.2.6 Protection................................................................................................................................................32
7.2.7 CANopen ................................................................................................................................................ 32
7.2.8 Diagnostics and drive information........................................................................................................... 32
7.2.9 Fault codes .............................................................................................................................................33
8 COMMISSIONING.............................................................................................................................. 36
8.1 Visual checks .............................................................................................................................................. 36
8.2 Checks before the first run.......................................................................................................................... 37
8.2.1 Power up procedure ...............................................................................................................................37
8.3 Test run without load ..................................................................................................................................39
8.4 Test run with load........................................................................................................................................40
8.5 After the test run .........................................................................................................................................41
9 OPERATING INSTRUCTIONS .......................................................................................................... 42
9.1 Control methods..........................................................................................................................................42
9.2 Slowdown-limit ............................................................................................................................................43
9.3 Stop-limit .....................................................................................................................................................43
10 MAINTENANCE............................................................................................................................. 44
10.1 Replacing the fan ........................................................................................................................................44
10.2 Spare parts .................................................................................................................................................44
11 TROUBLESHOOTING ................................................................................................................... 45
11.1 Problems and solutions ..............................................................................................................................45
11.2 Exceptional situations ................................................................................................................................. 45
11.2.1 Determining movement direction ........................................................................................................45
11.3 Warning and Fault codes ............................................................................................................................46
12 TAKING PRODUCT OUT OF OPERATION .................................................................................. 47
12.1 Disposal of waste materials ........................................................................................................................ 47
13 TECHNICAL DATA ........................................................................................................................ 48
14 CABLES AND FUSES ................................................................................................................... 49
15 QUICK GUIDE ............................................................................................................................... 50
15.1 Visual checks .............................................................................................................................................. 50
15.2 Checks before the first test run ................................................................................................................... 50
15.3 Check motor parameters ............................................................................................................................51
15.3.1 Compact brake motors (MF06MA, MF06LA)......................................................................................51
15.3.2 Other motors ....................................................................................................................................... 51
15.4 Autotuning ...................................................................................................................................................51
15.5 Manual tuning .............................................................................................................................................51
15.6 Test run without load ..................................................................................................................................52
15.7 Test run with load........................................................................................................................................52
15.8 After the test run .........................................................................................................................................53
16 APPENDIX 1, ELECTRICAL CONNECTIONS .............................................................................. 54
17 APPENDIX, CABLE CONNECTIONS ........................................................................................... 56
17.1 Conductor diameter and stripping lengths ..................................................................................................56
17.2 Recommended tightening torques.............................................................................................................. 56
18 APPENDIX 2, DEFAULT PARAMETERS WITH COMPACT BRAKE MOTORS........................... 57

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 3/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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 SERVICE MANUAL FOR FREQUENCY CONTROL
SYSTEM

Motor voltage

Parameter
(Example 02-03)

Fault
(Example FA06)

6.3 Navigation on the control keypad

The frequency converter is monitored and controlled with parameter groups. The parameters are identified with
“gg-pp”, where “gg” denotes a parameter group and “pp” a parameter within that group. Parameter group numbers
start from zero and parameter numbers from one.

Example: Parameter 02-03

6.3.1 Using butt ons

Up Down Left Right / OK Stop

6.3.2 Settin g parameters

Parameters are used for controlling and adjusting the functions of the frequency converter. Parameter values can
only be changed when the motor is not running.

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 25/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

6.3.3 Changing a parameter value

Press Left repeatedly until output value F (frequency), U
1 (voltage), or I (current) is shown.

Press OK.
2
Press UP or DOWN button repeatedly until the correct
3 parameter group (gg) is shown.

Press OK.
4
Press UP or DOWN button repeatedly until the correct
5 parameter (pp) is shown.
,

Press OK.
6
Press UP or DOWN button repeatedly until the correct
7 parameter value is shown.

Press OK. The value is stored and applied.

8

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 26/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

7 PARAMETERS
The listed parameters can be read from the display of the frequency converter.

Changing parameter s ettings dur ing r unning may cause a hazardous situation.
WARNING
Parameter settings must no t be changed during ru nning.

Incorrect parameter settings c an lead to u nexpected functi oning of the

CAUTION
equipment or personal injuri es.

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 27/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

7.1 General Description

Parameters are assorted to Groups as shown in the parameter tree:

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 28/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

7.2 PARA METER DESCRIPTIONS

Initially, the display shows the monitoring value “Output frequency” (F).
Pressing the (DOWN) button on the keypad shows the next monitoring value “Output voltage” (U) and output
current (I).
Pressing the (UP) button shows the previous monitoring value.

7.2.1 Viewing moni tor ing values (group 00)

The first parameter group, which is identified with a group number “00”, contains monitoring values. Monitoring
values show information about the current state of the frequency converter. Monitoring values differ from
parameters; the values can only be browsed with the keypad, not changed.
Monitoring values available are:
Code Parameter name Unit Range Default Descripti on

00-01 Brake relay state Output relay status:

Contact between RA and RC
0 or 1
0: Contact is open
1: Contact is closed.

00-02 MI port status Multi-function Input Terminal status.

Leftmost bit corresponds to DI1 state and the rightmost bit
corresponds to DI6 state. If the digital input is ON, then the
upper vertical bar of the bit is lit. If the digital input is OFF, the
lower vertical bar is lit

Example of value of parameter DI status

DI1 = ON
DI2 = OFF
DI3 = ON
DI4 = OFF
DI5 = ON
DI6 = ON
Notice.
Value 1 in parameters 05-01 (DI4), 05-02 (DI5) and 05-03
(DI6) will set the status of DI ”ON” even there is not voltage in
the input
Status indicator of digital inputs:
bit 0: DI1 status
bit 1: DI2 status
bit 2: DI3 status
bit 3: DI4 status
bit 4: DI5 status
bit 5: DI6 status

00-03 Motor current % Motor current as a percentage of the motor’s nominal current.

00-04 Motor voltage V Motor voltage.

00-05 IGBT temperature °C Insulated Gate Bipolar Transistor temperature.

00-06 DC link voltage V Voltage of DC link.

00-07 Frequency reference Hz Frequency reference before ramp generator.

00-08 Output frequency Hz Reference output frequency

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 29/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

00-09 Parameter lock 1 = disabled Parameter modifying on keypad

0 = enabled
1 = disabled

7.2.2 General
Code Parameter name Unit Range Default Descripti on

01-01 Accel time s 4.5 Acceleration time from zero to nominal frequency of motor.
0.1 - 30.0
Set: according the crane calculation

01-02 Decel time s 4.5 Deceleration time from nominal frequency of motor to zero.
0.1 - 30.0
Set: according the crane calculation

01-03 MinFrequency Hz 0.0 - 10 Minimum driving frequency

MaxFrequency Set: according the crane calculation

01-04 MaxFrequency Hz MinFrequency – From motor Maximum driving frequency

Motor nominal type plate Set: according the crane calculation
frequency

01-05 Slowdown frequency Hz 0.0 - 15 Maximum driving frequency in slowdown area

MaxFrequency Set: according the crane calculation

01-06 InputSet Selection of digital input function:

0: EP slow & stop
1: EP slow
2: MS slow & stop
0-5 3: MS slow
4: CAN slow & stop
5: CAN slow
Set: according the application

7.2.3 Motor
Code Parameter name Unit Range Default Descripti on

02-01 Motor Nominal Voltage V From motor Nominal voltage of motor.

50 - 500 type plate Set: from motor type plate

02-02 Motor Nominal Hz From motor Nominal frequency of motor.

Frequency 10.0 - 600.0 type plate Set: from motor type plate

02-03 Motor nominal current A Number of Sum of Nominal current of motors.

0.0 – 2 x
motors x Set: Number of motors x nominal current of one motor
Nominal current
nominal current
of TDN
of one motor

02-04 No-load current A Number of Current of motor without load.

0.0 – Nominal motors x no Set: Number of motors x no load current of one motor.
current of TDN load current of
If there is not Io in the name plate, set value to 0.
one motor

02-05 Current Limit A 1,5 x Nominal

0.0 - 2xNominal current of TDN Maximum output current.
current of TDN

02-06 DC_Brake Current Level A Current level during starting and stopping
Set:
0.0 – Nominal
current of TDN Disc brake motors: 80% of sum of motor nominal currents
Compact brake motors: number of motors x 3A, max 1.5 x
nominal current of TDN

02-07 Motor Cos Phi 0.8 Nominal cos phi of motor.

0.00 - 1.00
Set: from motor type plate

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 30/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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SERVICE MANUAL FOR FREQUENCY CONTROL

SYSTEM

02-08 Auto-tuning 0: Auto-tuning not done

1: Start auto-tuning
3: Auto-tuning completed successfully
4: Auto-tuning has failed
0-6 6: U/f parameters and Motor Stator Rs are modified after
successful auto-tuning

When set to value 1, auto-tuning will start, brake i s not

opened and motor will not run

02-09 Motor Stator Rs  Phase to phase resistance [ohms] of motor. Value is

automatically set during auto-tuning.
For compact brake motors, check value from chapter “Default
parameters with compackt brake motors” .

02-10 Motor Type 0 = Normal, DC-brake

1 = Compact brake
0 -1 With 1 / Compact brake motors, auto-tuning will not change
u/f-parameters nor Motor Stator Rs, check values from motor
parameter table.

7.2.4 U/f settings

Code Parameter name Unit Range Default Descripti on

03-01 Zero Frequency Voltage % Compact brake Output voltage in per cents of motor nominal voltage at zero
motors: from frequency.
table Set:
0.0 - 40.0 Normal motors: Normal motor: Do auto-tuning.
perform Auto-
Compact brake motors: Check value from chapter “Default
tuning
parameters with compackt brake motors”.

03-02 Mid-Point Voltage % Compact brake Output voltage in per cents of motor nominal voltage at mid-
motors: from point frequency.
table Set:
0.00 - 100.0 Normal motors: Normal motor: Do auto-tuning.
perform Auto-
Compact brake motors: Check value from chapter “Default
tuning
parameters with compackt brake motors”.
Note: The value is automatically set upon auto-tuning.

03-03 Mid-Point Frequency Hz Compact brake U/f curve mid-point frequency.

motors: from Set:
table
Normal motor: Do auto-tuning.
0.0 - 120.0 Normal motors:
Compact brake motors: Check value from chapter “Default
perform Auto-
parameters with compackt brake motors”.
tuning

7.2.5 Brake cont rol

Code Parameter name Unit Range Default Descripti on

04-01 Brake Opening Delay s 0.05 Delay after brake relay closing before frequency starts to
0.00 - 10.00
increase.

04-02 Stop DC frequency Hz 0.0 - 250 0.5 Frequency when Stop DC braking begins during stopping.

04-03 Start DC frequency Hz 0.0 - 250.0 2.0 Frequency when Start DC braking ends during starting.

04-04 DC Brake Time During s 0.10 DC braking time during stopping.

0.00 - 5.00
Stopping

04-05 Brake Close Frequency Hz 0.0 - 0.5 Frequency when the brake relay (RA) opens during stopping.
MaxFrequency

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 31/57
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.

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